Integrated process for producing anode grade coke

ABSTRACT

The invention relates to processes for producing anode grade coke from whole crude oil. The invention is accomplished by first deasphalting a feedstock, followed by processing resulting DAO and asphalt fractions. The DAO fraction is hydrotreated or hydrocracked, resulting in removal of sulfur and hydrocarbons, which boil at temperatures over 370° C., and gasifying the asphalt portion in one embodiment. This embodiment includes subjecting hydrotreated and/or unconverted DAO fractions to delayed coking. In an alternate embodiment, rather than gasifying the asphalt portion, it is subjected to delayed coking in a separate reaction chamber. Any coke produced via delayed coking can be gasified.

RELATED APPLICATION

This application is a divisional of application Ser. No. 15/219,730filed Jul. 26, 2016, which claims priority from U.S. ProvisionalApplication No. 62/200,830 filed Aug. 4, 2015, both incorporated byreference in their its entirety.

FIELD OF THE INVENTION

The invention relates to an integrated process for treating whole crudeoil to remove asphalt and other impurities therefrom, and then produceanode grade coke from the treated crude oil. To elaborate, theintegrated process comprises the steps of separating asphalt from thewhole crude oil, followed by treating the deasphalted oil (“DAO”) viahydrotreatment/hydrocracking with a catalyst, to remove materials suchas sulfur and nitrogen. The hydrotreated or unconverted DAO fraction isthen subjected to delayed coking. In parallel, the recovered, asphaltcontaining fraction can be gasified, to produce hydrogen that is thenused in the hydrocracking step.

BACKGROUND AND PRIOR ART

Conventional processes for treating crude oil involve distillation, andthen various cracking, solvent refining, and hydroconversion processes,so as to produce a desired group of products, such as fuels, lubricatingoil products, petro-chemicals, chemical feedstocks, and the like. Anexemplary process includes the distillation of the crude oil in anappropriate atmospheric distillation column, resulting in gas oil,naphtha, other gases, and atmospheric residuum. This last portion isfractionated further in a vacuum distillation column, so as to produceso-called vacuum gas oil, and vacuum residuum. The vacuum gas oil, inturn, is usually cracked via fluid catalytic cracking or hydrocracking,to produce more valuable light transportation fuel products, while theresiduum can be processed further, to yield additional useful products.The methods involved in these processes can include, e.g., hydrotreatingor fluid catalytic cracking of the residuum, coking, and solventdeasphalting. Any materials recovered from crude distillation at fuelboiling points have typically been used, directly, as fuels.

To elaborate on the processes described, supra, solvent deasphalting isa physical, separation process, where feed components are recovered intheir original states, i.e., they do not undergo chemical reactions.Generally, a paraffinic solvent, containing 3-7 or 8 carbon molecules,is used to separate the components of the heavy crude oil fractions. Itis a flexible process, which essentially separates atmospheric, andvacuum heavy residues, typically into two products: (i) asphalt and (ii)deasphalted or demetallized oil, referred to as “DAO” or “DMO,”respectively hereafter. The choice of solvent is left to the skilledartisan, and is chosen with desired products, yields, and quantities inmind, as are other process parameters, such as the operatingtemperature, operating pressure, and the solvent/oil ratio. As a generalrule, as the molecular weight of the solvent increases, so doessolubility of the oil into the solvent. For example, either propane or apropane/isobutane mixture is typically used to manufacture lube oilbright stock. If, on the other hand, the DAO will be used in conversionpractices, like fluid catalytic cracking, solvents with higher molecularweights (e.g., butane or pentane, or mixtures thereof), are used. Theproducts of DAO solvation include those described supra, as well as lubehydrocracking feed, fuels, hydrocracker feed, fluid catalytic crackingfeed, and fuel oil blends. The asphalt product may be used as a blendingcomponent for various grades of asphalt, as a fuel oil blendingcomponent, or as a feedstock for heavy oil conversion units (e.g.,cokers.)

Conventional solvent deasphalting methods are carried out withoutcatalysts or adsorbents. U.S. Pat. No. 7,566,394, the disclosure ofwhich is incorporated by reference, teaches improved solventdeasphalting methods which employ solid adsorbents. The improvement inthe methodology leads to separation of nitrogen and polynucleararomatics from DAO. The adsorbents are then removed with the asphaltproducts, and are either sent to an asphalt pool, or gasified in amembrane wall gasifier, where solids are required.

Hydrocracking processes, as is well known, are used commercially in manyrefineries. A typical application of a hydrocracking process involvesprocessing feedstreams which boil at 370° C. to 565° C. in conventionalunits, and those which boil at 520° C. and above, in so-called “residueunits.” Simply stated, hydrocracking is a process by which C—C bonds oflarge molecules in a feedstream, are broken, to form smaller molecules,which have higher volatility and economic value. In addition,hydrocracking processes typically improve the quality of hydrocarbonfeedstock, by increasing the H/C ratio via hydrogenation of aromaticcompounds, and by removing organo-sulfur, and organic nitrogencompounds.

Given the significant economic benefits that result from hydrocracking,it is not surprising that there have been substantial developments inimproving hydrocracking processes, and the development of more activecatalysts.

In practice, hydrocracking units usually include two principal zones: areaction zone and a separation zone. There are also three standardconfigurations: single stage, series-flow (“once-through”), with andwithout recycling, and two stage processes, with recycling. The choiceof reaction zone configuration depends upon various parameters, such asfeedstock quality, the product specification and processing objectives,and catalyst selection.

Single stage, once-through hydrocracking processes are carried out atoperating conditions which are more severe than typical hydrotreatingprocesses, but which are less severe than conventional full pressurehydrocracking processes. Mild hydrocracking is more cost effective thanmore severe processes but, generally, it results in production of lesseramounts of desired middle distillate products, which are of lowerquality than the products of conventional hydrocracking.

Single or multiple catalyst systems can be used depending upon, e.g.,the feedstock processed and product specifications. Single stagehydrocracking units are generally the simplest configuration, designedto maximize middle distillate yield over a single or dual catalystsystem. Dual catalyst systems are used in stacked-bed configurations orin two different reactors.

Feedstock is typically refined over one or more amorphous-basedhydrotreating catalysts, either in the first catalytic zone in a singlereactor, or in the first reactor of a two-reactor system. The effluentsof the first stage are then passed to the second catalyst system whichconsists of an amorphous-based catalyst or zeolite catalyst havinghydrogenation and/or hydrocracking functions, either in the bottom of asingle reactor or the second reactor of a two-reactor system.

In two-stage configurations, which can also be operated in a“recycle-to-extinction” mode of operation, the feedstock is refined bypassing it over a hydrotreating catalyst bed in the first reactor. Theeffluents, together with the second stage effluents, are passed to afractionator column to separate the H₂S, NH₃, light gases (C₁-C₄),naphtha and diesel products which boil at a temperature range of 36-370°C. The unconverted bottoms, free of H₂S, NH₃, etc. are sent to thesecond stage for complete conversion. The hydrocarbons boiling above370° C. are then recycled to the first stage reactor or the second stagereactor.

Hydrocracking unit effluents are sent to a distillation column tofractionate the naphtha, jet fuel/kerosene, diesel, and unconvertedproducts which boil in the nominal ranges of 36-180° C., 180-240° C.,240-370° C. and above 370° C., respectively. The hydrocracked jetfuel/kerosene products (i.e., smoke point >25 mm) and diesel products(i.e., cetane number >52) are of high quality and well above worldwidetransportation fuel specifications. While hydrocracking unit effluentsgenerally have low aromaticity, any aromatics that remain will lower thekey indicative properties of smoke point and cetane numbers for theseproducts.

One major technical challenge posed in hydrotreating and/orhydrocracking heavy oil fractions or whole crude is the effect of smallconcentrations of contaminants, such as organic nickel or vanadiumcontaining compounds, as well as poly nuclear aromatic compounds. Theseorganometallic compounds, and others, reduce the activity or lifetime ofhydrotreating catalysts. The contaminants and polynuclear aromaticscause reduced process performance, a need for increased capital, andhigher operating costs for refinery processing units. The metals in theresidual fraction of the crude oil deposit on the hydroprocessingcatalyst pores and results in catalyst deactivation. These problems areaddressed and solved in the disclosure which follows.

Conventional, prior art processes in the field of the invention involvedistillation of crude oil, followed by treatment of the light fractions(naptha and diesel fuel) which remain following distillation. Theselight fractions are desulfurized and/or treated (i.e., “reforming” inthe case of naphtha) to improve their quality, and are then sent to fuelpools for further use. The vacuum residium, referred to supra, istreated via solvent deasphalting, so as to secure deasphalted oil andasphalt. Asphalt is then further treated, by being gasified, or it issent to the “asphalt pool.”

Prior art processes show the treatment of fractionates or distillates ofcrude oil, rather than treatment of crude oil per se, as in accordancewith the invention. See, e.g., PCT/EP2008/005210 where distillates areused to produce asphaltenes and DAO; U.S. Pat. No. 3,902,991, wherein avacuum residuum is solvent extracted followed by hydrocracking andgasification of the DAO and asphalt; published U.S. Patent Application2011/0198266, showing treatment of a vacuum residue; published U.S.Patent Application 2008/0223754, where residues from a distillationprocess are used to manufacture asphaltene and DAO; and EP 683 218,which also teaches treating residual hydrocarbon products. Also see,e.g., U.S. Pat. Nos. 8,110,090; 7,347,051; 6,357,526; 6,241,874;5,958,365; 5,384,297; 4,938,682; 4,039,429; and 2,940,920, as well asPublished U.S. Patent Application 2006/0272983; PCT/KR2010/007651,European Patent Application 99 141; and Published Japanese PatentApplication 8-231965. All references discussed herein are incorporatedby reference in their entirety.

The current invention simplifies and improves the prior art process, byeliminating the need for distillation, and for treating the naptha anddiesel fractions. Rather, the invention, as will be seen, simplifieswhole crude oil processing by hydrocracking the whole stream, andeliminating the steps referred to supra, while providing a method fordelayed coking of fractions produced by the method.

How the invention is achieved will be seen in the disclosure whichfollows.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a schematic depiction of the process of the invention,using a single reactor embodiment to reduce hydrocarbon containingfeedstock.

FIG. 2 shows an embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The invention may be best understood by referring to FIGS. 1 and 2,which illustrates the general method of the invention as well as asystem used in its practice.

Referring to FIG. 1, a feedstream of crude oil “10” is added to areaction chamber “11,” so as to solvent deasphaltize (SDA) it, therebyproducing an asphalt fraction “12,” and a fraction of deasphalted oil,or “DAO 13” as referred to supra. The manner in which this fractionationcan be accomplished is described, supra, i.e., a paraffinic solventcontaining one or more carbon atoms containing from 3-8, more preferably3-7 carbons, is used. No catalyst or adsorbent is necessary; however,see U.S. Pat. No. 7,566,394, incorporated by reference, supra, teachingan improved deasphalting process using a sorbent. No distillation isused, nor are the light components separated.

The “DAO” “13” is transferred to a hydrocracking/hydrotreating zone“14.” It is to be understood that, while FIG. 1 describes a singlereactor, the various methods for hydrocracking, including “once through,series flow,” and “two-stage” reactions, may all be used. The reactorcontains one or more catalysts which remove heteroatoms, such as sulfurand nitrogen from the DAO. Such catalysts are well known to the art, andare not repeated herein. Exemplary of such are catalysts described in,e.g., PCT/US11/46272 filed Aug. 2, 2011 and incorporated by referenceherein. The cracking reaction takes place in the presence of hydrogen,which is supplied as explained infra.

It will be recalled that in addition to the DAO, solvent deasphalting ofthe crude oil produces an asphalt fraction “12.” This asphalt fractionis transferred to a gasification chamber “15,” together with oxygen andsteam, which are not shown. These components, i.e., the oxygen andsteam, may be supplied in pure form, or via, e.g., atmospheric air. Theasphalt, oxygen and steam are combined, at temperatures and pressureswhich result in production of hydrogen. In the depicted embodiment, thishydrogen “18,” is channeled to the DAO hydrocracking unit “14,” tosupply the hydrogen necessary for the hydrocracking process to takeplace. (It should be noted that the gasification of asphalt is anoptional step, and may be replaced via, e.g., supplying an independentsource of hydrogen). Various products, e.g., gases 19, and upgradedcrude oil (distillates) 20, result, as well as unconverted DAO 21. Thisunconverted DAO is transmitted to a delayed coking chamber 22, andconverted to anode grade coke 23, gases 24, and further distillates 25.

Turning to FIG. 2, as with FIG. 1, a source of crude oil 31 is providedto a solvent deasphalting unit 32. Following standard methods,deasphalted oil (“DAO”) 33, and asphalt 34 are produced. The DAO istransmitted to a hydrocracking or hydrotreating chamber 35, suppliedwith hydrogen 36, which can be provided as per the description supra.The products of standard hydrocracking are gases 37, distillates 38, andunconverted DAO 39, which moves to a delayed coking unit 40, where it isprocessed to gases 41, distillates 42, and anode grade coke 43.

Further processing of asphalt 34 takes place in a further chamber anasphalt oxidation chamber 44, where the asphalt can be oxidized with,e.g., air to produce higher grade asphalt, or it too may be subjected todelayed coking to produce fuel grade coke. The asphalt 45 can be sent toan asphalt pool.

By separating the asphalt component of the crude oil from the DAO, oneeliminates problems such as the failing of catalysts by metals that arepresent in the asphalt fraction. Catalyst life cycles are increased, andthe need for shut downs of reactors, and replacement of materials, aredecreased.

In the process as described herein, the hydrocracking process takesplace at standard hydrocracking conditions, i.e., pressures ranging fromabout 100 to about 200 bars, temperatures ranging from about 350° C. toabout 450° C., LHSVs of between 0.1 and 4.0 h⁻¹, and hydrogen oil ratiosof from about 500 to about 2,500 SLt/Lt.

Following this step, any hydrotreated, or unconverted DAO fraction movesto a third reaction chamber where it is subjected to delayed coking.

Example 1

This example describes an embodiment of the invention in whichgasification of the “SDA” fraction was used to produce hydrogen, whichwas then used in the hydrocracking of the DAO fraction. It will beunderstood that the H₂ may be supplied via other means.

A 1000 kg sample of crude oil was solvent deasphalted, using art knowntechniques, with butane solvents and adsorbents, in a reaction chamber,such as is depicted by “11” in FIG. 1. Prior to deasphalting, the crudeoil was analyzed, and the results of this analysis are presented in theTable, column 1, which follows.

Following deasphalting, the asphalt fraction and deasphalted oil, or“DAO,” were also analyzed, and these results are presented in columns 2and 3 of the Table.

The asphalt fraction was gasified by oxygen and steam combining it intomembrane wall reactor or gasification chamber, depicted at “15” inFIG. 1. The mixture was heated to 1045° C., with a water to carbon ratioof 0.6 (in terms of weight), and an oxygen:pitch ratio of 1.0.

After gasification was completed, the raw syngas product was combinedwith steam that was produced by either a boiler or process heatexchanger to a water gas shift (“WGS”) reactor, which was operated at318° C., one bar of pressure, and a water to hydrogen ratio of 3. Thisincreased hydrogen yield.

All analyses and results are presented in the table which follows andwhich is elaborated upon infra:

TABLE 1 Summary of Components Column # 1 2 3 4 5 6 7 8 Stream ArabDeasphalted Asphalt C1-C4 Upgraded Oxygen Steam Hydrogen Name Heavy COCrude Oil Crude Oil Feedrate kg 1000 922 78 4.8 930 78 46.8 13 DensityKg/Lt 0.8904 0.876 1.210 0.825 API Gravity * 27.4 30.0 −14.6 40.1 CarbonW % 84.8233 85.04 78.36 Hydrogen W % 12.18 12.83 6.43 Sulfur W % 2.8371.99 10.79 <20 Nitrogen ppmw 1670 535 9575 <20 MCR W % 8.2 2.55 61.3Nickel ppmw 16.4 1 582 <1 Vanadium ppmw 56.4 1 172 <1 C5-Asphaltenes W %7.8 C7-Asphaltenes W % 4.2 Toluene insolubles W % 0.0008 Ashes W % 0.014H2 W % 99.5 H2S W % 2.47 NH3 W % 0.11 C1-C4 W % 100  36-190 W % 17.420.6 21.5 190-370 W % 25.8 29.0 36.0 370-490 W % 17.9 19.1 21.2 490+- W% 39.0 31.3 21.2

While gasification was taking place, the DAO portion was introduced to astandard, hydrocracking unit, shown in “14,” and hydrocracked at 360°C., 115 bars of hydrogen partial pressure, with an overall liquid hourlyspace velocity of 0.3 h⁻¹, with a Ni—Mo promoted, amorphous VGOhydrocracking catalyst and a zeolite catalyst designed for heavy oils,at a loading ratio of 3:1. See PCT/US11/46272, incorporated supra, forthe catalyst used herein.

Also encompassed are compositions where catalysts are presented on asupper, such as an alumina, silica, or zeolite support. Exemplaryzeolite supports have FAU, MOR, BEA, OR MFI topology. See, e.g., U.S.Pat. Nos. 3,875,290; 3,948,760; and 4,346,067, all of which areincorporated by reference.

The products which left the hydrocracking chamber were analyzed forcontent of low molecular weight hydrocarbons (C₁-C₄), upgraded crudeoil, oxygen, steam, and hydrogen. These values are presented in columns4-5 in Table 1. The upgraded crude oil was also analyzed for variousminor components, as well as boiling fractions, in the same way thecrude oil, and DAO were analyzed. To elaborate upon Table 1, Column 1presents the analysis of the crude oil (“CO”) used in the reaction.Column 2 is the analysis of the resulting DAO and Column 3, the asphaltfraction. Column 4 presents the information on the gas produced in thehydrocracking step, with Column 5, the upgraded crude oil. Finally,Columns 6, 7, and 8 refer to the reactants added to the reactors, asdiscussed supra.

Example 2

A 1000 kg sample of crude oil was solvent deasphalted using butanesolvents and adsorbents, and techniques known to the art. Prior to this,the crude oil was analyzed, and the results are shown in column 1 ofTable 2, which follows.

Following the deasphalting, both the asphalt fraction and the DAO wereanalyzed, and these results are also set forth in Table 2 as columns 2and 3.

The DAO portion was introduced to a standard hydrocracking unit, andhydrocracked at 360° C., 115 bars hydrogen partial pressure, and anoverall liquid hourly space velocity of 0.3 h⁻¹. As catalysts, a Ni—Mopromoted, amorphous VGO hydrocracking catalyst, and a zeolite catalystdesigned for heavy oils were used, at a loading ratio of 3:1.

Products leaving the hydrocracking chamber were analyzed for each of:(i) low molecular weight hydrocarbons (C₁-C₄), upgraded crude oil,oxygen, steam and hydrogen. All values are presented in Table 2.

The resulting upgraded fuel oil was then fractionated, using standardtechniques, to secure gas distillates, and unconverted DAO. Theunconverted DAO was then transmitted to a delayed coking unit, andsubjected to standard processes to secure anode grade coke, distillates,and gases. Again, values are given in Table 2.

Stream# 1 2 3 4 5 6 7 8 9 10 Stream Arab Deasphalted Asphalt C1-Upgraded Hydrogen Uncoverted Anode Gases Distillates Name Heavy CrudeOil C4 Crude Oil DAO Grade CO Coke Feedrate kg 1000 922 78 9.5 934 21148 13 12 126 Density Kg/Lt 0.8904 0.876 1.210 0.811 API Gravity — 27.430.0 −14.6 43.0 Carbon W % 84.8233 85.04 78.36 Hydrogen W % 12.18 12.836.43 Sulfur W % 2.8297 1.99 10.79 <20 <1 Nitrogen ppmw 1670 535 9575 <20MCR W % 8.2 2.55 61.3 Nickel ppmw 16.4 1 582 <1 <1 Vanadium ppmw 56.4 1172 <1 <1 C5- W % 7.8 Asphaltenes C7- W % 4.2 Asphaltenes Toluene W %0.0008 insolubles Ashes W % 0.014 Composition W % — — — H2 Kg/h 0.000.00 0.00 0.00 0.00 21.03 0.00 0.00 0.00 H2S Kg/h 0.00 0.00 0.00 0.0023.01 0.00 0.00 0.00 0.00 NH3 Kg/h 0.00 0.00 0.00 0.00 1.01 0.00 0.000.00 0.00 C1-C4 Kg/h 0.00 0.00 0.00 9.47 0.00 0.00 0.00 9.18 0.00 36-190Kg/h 17.4 20.6 0.00 0.00 224.59 0.00 0.00 0.00 18.72 190-370 Kg/h 25.829.0 0.00 0.00 371.80 0.00 0.00 0.00 55.86 370-490 Kg/h 17.9 19.1 0.000.00 189.46 0.00 0.00 0.00 51.40 490+- Kg/h 39.0 31.3 0.00 0.00 147.820.00 147.82 0.00 125.98

The foregoing disclosure sets forth the features of the invention, whichis a simplified methodology for delayed coking of hydrotreated and/orunconverted DAO fractions produced when eliminating impurities inhydrocarbon containing feedstocks, such as crude oil, which does notinvolve distillation. To summarize, the crude oil is solventdeasphalted, resulting in DAO and asphalt. The DAO is then hydrocrackedin the presence of a catalyst so as to desulfurize and denitrogenize it,and to convert any hydrocarbons, which have a boiling point over 370° C.into distillates. Any hydrotreated or unconverted DAO fractions are thensubjected to delayed coking. Concurrently, the asphalt fraction isgasified so as to produce hydrogen. In one embodiment, the hydrogen ischanneled back into the hydrocracking reactor and used in that process.The nature of the gasification feedstock will, of course vary and mayinclude ash in an amount ranging from about 2% to about 10% of the totalfeedstock. The feedstock may be liquid or solid. Liquid feedstockshaving components with boiling points of from about 36° C. to about2000° C. are preferred. The feedstock may be, e.g., crude oilbituminous, oil, sand, shale oil, coal, or a bio liquid.

In practice, it is desirable to subject the crude oil to a paraffinicsolvent to separate DAO and asphalt. The solvent comprises one or moreC₃-C₇ alkanes, which may be straight chained or branched. Preferably,the solvent comprises one or, most preferably, a mixture of butanes.Solvation takes place at temperatures and pressures, which are below thecritical values for both of these.

It is especially preferred to carry out the deasphalting step,discussed, in the presence of a solid adsorbent, preferably added in anamount sufficient to provide a hydrocarbon:adsorbent ratio of from20:0.1 to 10:1, expressed in terms of W/W.

After separation, the DAO is transmitted to a hydrocracking unit, wherehydrocracking is carried out at conditions which may vary, but arepreferably a pressure of from about 100 to about 200 bars, a temperatureof from about 350° C. to about 450° C., an LHSV of from about 0.1 toabout 4.0 h⁻¹, and a hydrogen:oil ratio of from about 500 to about 2500SLt/Lt. Any standard hydrocracking system may be used including singlereactors, multiple reactors operated in series, fixed bed reactors,ebullated bed reactors, and so forth.

A catalyst is used in the hydrocracking process, preferably the catalystincorporated by reference supra. Preferably, the catalyst contains fromabout 2% to about 40% by weight of active metal, a total pore volume offrom about 0.3 to about 1.5 cc/g, a total surface area of from about 200to about 450 m²/g, and an average pore diameter of at least 50angstroms.

With respect to the active metal, referred to supra, metals from GroupVI, VII or VIIIB are preferred, and may include one or more of Co, Ni,W, and Mo. While it is not required to do so, the catalysts aregenerally incorporated on a support, such as alumina, silica, a zeoliteor a zeolite modified by, e.g., steam, ammonia, acid washing and/orinsertion of transition metals into its structure. The zeolite, if used,may have FAU. MOR, BEA, or MFI topology.

Concurrent with the hydrocracking of the DAO and the delayed coking, theasphalt portion of the crude oil is gasified in a gasification chamber,e.g., a membrane wall type reactor, preferably at a temperature of fromabout 900° C. to about 1700° C., and a pressure of from about 20 bars toabout 100 bars. Gasification takes place in the presence of an O₂containing gas, which may be, e.g., pure O₂ or more preferably, air.Means may be provided to control the amounts of asphalt and oxygenentering the gasification reactor. Such means are well known to theskilled artisan and need not reiterated here. It is preferred to controlthe amounts of asphalt and O₂, so that a stoichiometric balancepermitting partial combustion ensues. This can be determined viadetermining the hydrocarbon content of the crude oil, such as was donein the example, supra. Preferably, the amounts are selected such thatthe oxygen:carbon ratio ranges from about 0.2:1.0 to about 5:0.1 byweight. Any coke produced in the delayed coking step discussed above maybe gasified to produce hydrogen.

Optionally, steam may be added to the gasification chamber. When it is,it too is added in an amount based upon the carbon content of the crudeoil, and is preferably presented at a ratio of from about 0.1:1.0 toabout 100:1.0 by weight. Gasification results in a product sometimesreferred to as “syngas” consisting essentially of hydrogen and carbonmonoxide. In one embodiment of the invention, the syngas produced bygasification is transmitted to a water gas shift reaction chamber andtreated to produce H₂ and CO₂, after which H₂ is separated. Theresulting, pure H₂ may be channeled to the hydrocracking reaction.

The process by which the syngas is treated may include treatment at atemperature of from about 150° C. to about 400° C., and a pressure offrom about 1 to about 60 bars.

As was seen, supra, gas content can be measured at any point in theprocess described here. Hence, following measurement of CO content inthe syngas, water can be added to the reaction chamber, preferably at amolar ratio with CO of from about 3:1 to about 5:1.

Other facets of the invention will be clear to the skilled artisan andneed not be reiterated here.

The terms and expression which have been employed are used as terms ofdescription and not of limitation, and there is no intention in the useof such terms and expression of excluding any equivalents of thefeatures shown and described or portions thereof, it being recognizedthat various modifications are possible within the scope of theinvention.

The invention claimed is:
 1. A method for producing anode grade coke,comprising: solvent deasphalting a hydrocarbon feedstock to produce anasphalt fraction and a deasphalted oil (DAO) fraction, in a firstreaction chamber; processing said DAO fraction and asphalt fraction inseparate, second, third, and fourth reaction chambers; (iii)hydrocracking said DAO fraction in said second reaction chamber in thepresence of a catalyst, which contains from 2-40 wt % active metal, apore volume of from 0.33-1.50 cc/gm, a surface area of 250-450 m²/g, andan average pore diameter of at least 50 Angstroms to remove sulfur andnitrogen therefrom and to distill any hydrocarbons contained in said DAOfraction which have a boiling point over 370° C.; (iv) subjecting anyhydrotreated or unconverted DAO fraction to delayed coking in a thirdchamber, and (v) gasifying said asphalt fraction via combining it withoxygen and steam, in said fourth reaction chamber, to produce hydrogentherefrom.
 2. The method of claim 1, further comprising gasifying anycoke produced in step (iv).
 3. The method of claim 1, comprisingintroducing and hydrogen produced in said third reaction chamber intosaid second reaction chamber.
 4. The method of claim 1, wherein saidhydrocarbon feedstock is crude oil and said solvent deasphaltingcomprises mixing said crude oil with a paraffinic solvent containingC₃-C₇ carbon atoms, at a temperature and a pressure below criticaltemperature and critical pressure of said solvent.
 5. The method ofclaim 4, wherein said solvent comprises n-butane and isobutane.
 6. Themethod of claim 4, further comprising contacting said crude oil with asolid adsorbent.
 7. The method of claim 4, wherein said solventcomprises a mixture of butanes.
 8. The method of claim 4, wherein saidcrude oil and solvent are combined at a weight ratio of from 10:1 to200:1 w/w.
 9. The method of claim 1, comprising hydrocracking said DAOin a series of multiple chambers.
 10. The method of claim 1, whereinsaid second reaction chamber is a hydrocracking chamber and is a fixedbed, ebullated bed, or slurry bed chamber.
 11. The method of claim 1,wherein said active metal is a Group VI, VII, or VIIIB metal.
 12. Themethod of claim 1, wherein said active metal comprises Co, Ni, W, or Mo.13. The method of claim 1, wherein said catalyst is presented on asupport.
 14. The method of claim 13, wherein said support comprisesalumina, silica, or a zeolite.
 15. The method of claim 14, wherein saidsupport is a zeolite with FAU, MOR, BEA or MFI topology.
 16. The methodof claim 15, wherein said zeolite has been modified by treatment with atleast one of steam, ammonia, or acid, and contains at least onetransition metal.
 17. The method of claim 16, wherein said at least onetransition metal is Zn or Ti.
 18. The method of claim 1, comprisinggasifying said asphalt fraction at a temperature of from 900° C. to1700° C., a pressure of from 20 bars to 100 bars, and an O₂ containinggas.
 19. The method of claim 18, wherein said O₂ containing gas is pureO₂, air, or steam.
 20. The method of claim 18, comprising adjusting theamount of said asphalt fraction and said oxygen containing gas toprovide a stoichiometric balance therebetween which results in partialcombustion of said asphalt.
 21. The method of claim 18, wherein said O₂from said O₂ containing gas and carbon from said asphalt fraction arepresent at a ratio of from 0.2:1.0 to 10:0.2 by weight.
 22. The methodof claim 19, wherein said O₂ containing gas is steam, said methodfurther comprising introducing said asphalt fraction and steam to saidfourth reaction chamber at a ratio of from 0.1 to 1.0 to 10:0.1, basedupon weight of carbon in said feedstock, wherein said feedstock is crudeoil.